Board with pre-applied sealing material
A board with preformed seals. In an exemplary embodiment, a sealing material is applied to at least one edge of a board to form a preformed seal on that edge. The board is configured such that when the board is attached to a frame adjacent to a another board, at least a portion of the sealing material applied to the edge of the board seals against at least a portion of an edge another board. In one exemplary embodiment, the boards are configured to seal against edges of substantially identical boards. A plurality of the sheathing boards may be installed on a building frame to form a sheathing system that provides a moisture and/or gas barrier between and interior and exterior of a building.
Latest Owens Corning Intellectual Capital, LLC Patents:
This application is a divisional application of U.S. Ser. No. 15/177,664 entitled “Board with Pre-Applied Sealing Material” filed Jun. 9, 2016, which is a divisional application of U.S. Ser. No. 13/073,170 entitled “Board with Pre-Applied Sealing Material” filed Mar. 28, 2011, the disclosures of which is incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTIONIn constructing a building, and in particular a house, a relatively thin panel board is commonly used to cover the structural framework of exterior walls. The board is typically fabricated from a low-cost, lightweight material having enhanced insulating properties, such as for example extruded or expanded polystyrene, polyisocyanurate or polyurethane foam. Usually, the boards are sized for use in conjunction with conventional frame sections (that is, frames with wooden studs on 16 inch (40.64 cm) or 24 inch (60.96 cm) centers). The boards may also have varying thicknesses and compositions, depending on, among other considerations, the desired resistance to heat flow.
In some applications an air and water or moisture barrier is provided between the interior and the exterior of the building. This air and moisture barrier may be achieved using a layer of a plastic sheet known as a water resistive barrier in conjunction with the boards. The air and moisture barrier may also be achieved by taping the joints where the boards abut one another.
SUMMARYA board with preformed seals is disclosed. In one exemplary embodiment, a sealing material is applied to at least one edge of a board. The board is configured such that when the board is attached to a frame adjacent to a another board, at least a portion of the sealing material applied to the edge of the board seals against another board or other structure. In one exemplary embodiment, the boards are configured to seal against edges of substantially identical boards.
In an exemplary embodiment, a plurality of the boards may be installed on a building frame to form a sheathing system that provides a moisture and/or gas barrier between and interior and exterior of a building. For example, a first board with the pre-applied sealing material may be attached to the frame. A second board with preformed seal may then be attached to the frame at a position where at least a portion of the sealing material of the first board seals against at least a portion of an edge of the second board. This process may be repeated to provide a wall of material that provides an air and/or moisture barrier between an exterior and an interior of the building.
In one exemplary embodiment, a sealing material is applied to at least one face of a board along at least one edge of the board. The board is configured such that when the board is attached to a frame, at least a portion of the sealing material applied along the edge of the board seals against the frame.
In the accompanying drawings which are incorporated in and constitute a part of the specification, embodiments of the invention are illustrated, which, together with a general description of the invention given above, and the detailed description given below, serve to example the principles of this invention.
As described herein, when one or more components are described as being connected, joined, affixed, coupled, attached, or otherwise interconnected, such interconnection may be direct as between the components or may be indirect such as through the use of one or more intermediary components. Also as described herein, reference to a “member,” “component,” or “portion” shall not be limited to a single structural member, component, or element but can include an assembly of components, members or elements.
The present application discloses exemplary embodiments of boards 10 with preformed seals 12 (see
In this application, preformed seals 12 are seal members that are formed before the boards 10 are attached to a frame 34, for example to construct a sheathing system. For example, the preformed seals 12 may be formed by pre-applying sealing material 32 to a board at a remote location, such as a factory. The sealing material 32 may dry or otherwise cure to form the preformed seals.
Referring to
The frame members 34 may take a variety of different forms. For example, the frame 34 may comprise conventional wood or metal framing studs that are typically used to frame houses and other buildings. Any type of material capable of supporting the boards 10 may be used. The boards 10 with preformed seals 12 may be assembled to the frame 34 with conventional fasteners, such as staples, nails, screws, and/or adhesive. Each board 10 with preformed seal(s) 12 is positioned to seal against an edge of one or more other boards and is then fastened to the frame members 34.
The board 10 with preformed seals 12 is positioned 52 (see
Once in position, the boards 10 with preformed seals 12 are secured 54 (
The boards 10 may be arranged in a variety of different patterns to form a system 14 that acts as a barrier against air and/or moisture between the outside 60 (
The boards 10 with seals 12 may be configured to be used with identical boards with seals and/or the boards 10 with seals 12 may be configured to be used with differently configured boards. In the example illustrated by
In the
The boards 18 can be made from a wide variety of different materials and combinations of materials. Examples include, but are not limited to, oriented strand board (OSB), plywood, foam materials, such as, polystyrene, extruded polystyrene, expanded polystyrene, molded polystyrene, polyisocyanurate, polyurethane, any open or closed cell foam material, reinforced foam materials, such as polystyrene, extruded polystyrene, expanded polystyrene, molded polystyrene, polyisocyanurate, polyurethane with a reinforcement skin laminated on one or both sides, and composite materials, such a as composites of any one or more of OSB, plywood, any of the foam materials listed above, fiberglass reinforced sheets, the sheathing material or any component or combination of the components of the sheathing material that is described in U.S. Pat. No. 6,715,249 to Rusek et al. (which is incorporated herein by reference in its entirety). The boards may comprise any product capable of being provided in a rigid or semi-rigid sheet or board form.
The boards 18 may take a variety of different configurations. The boards 18 may have a variety of different thicknesses. For example, the boards 18 may be foam boards that are ½″, ¾″, 1″ or up to 4″ thick. In some embodiments, the boards are thin. For example, in the embodiments illustrated by
The boards 18 may have a variety of different shapes. For example, the boards 18 may be polygonal, such as triangular, square, rectangular, hexagonal, etc. Edges that include the seal material 32 may take a wide variety of different forms. The edges that include the seal material 32 may include projections and/or channels. Edges that do not include seal material may also take a wide variety of different forms. The edges that do not include the seal material 32 may include projections and/or channels. The edges of the board 18 that will receive seal material 32 may be the same or different than the edges of the board that will not receive seal material 32.
The sealing material 32 may take a wide variety of different forms. Examples of suitable sealing materials 32 include, but are not limited to, spray foam materials, such as Energy Complete available from Owens Corning, polystyrene, extruded polystyrene, expanded polystyrene, polyisocyanurate, polyurethane, and any compressible sealing foam that stays flexible when cured. The sealing material 32 can be open or closed cell and can be applied such that when two boards 10 are abutted or joined in the case of a ship lap or lip edge (see
Referring to
The preformed seal 12 may have a wide variety of different configurations. Any shape and size of seal 12 that facilitates sealing between the seal 12 and an edge of an adjacent board 10 and/or between the seal 12 and a seal of an adjacent board may be used. The preformed seal 12 may be formed by spray application to the board 18, extrusion onto the board, molding onto or with the board, preforming a gasket that is attached to the board with an adhesive, etc. In the example illustrated by
The preformed seal 12 may be secured to the edge(s) of the board 18 in a wide variety of different ways. In the example illustrated by
In the example illustrated by
In the examples illustrated by
The seal material 32 is applied on the lips 80. The seal material may be applied in a variety of different ways. In the embodiments illustrated by
Referring to
Once in position, the boards 10 with preformed seals 12 are secured to the frame members 34. Securing the boards 10 to the frame members permanently sets the relative positions of the boards 10, which in turn makes the seals 12 between the boards 18 and the frame members 34 permanent. This process may be repeated as many times as necessary to form a system 14 that acts as an air and/or moisture barrier.
Any one or more of the features of the different embodiments of boards 10 with preformed seals, sheathing systems 14 and methods 16 disclosed by the application may be used in any combination or sub-combination. Further, while the present invention has been illustrated by the description of embodiments thereof, and while the embodiments have been described in considerable detail, it is not the intention of the applicants to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. Therefore, the invention, in its broader aspects, is not limited to the specific details, the representative apparatus, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the applicant's general inventive concept.
Claims
1. A method of applying a sheathing system to a frame, the method comprising:
- applying a compressible foam sealing material to a rigid board having a front face and a back face, wherein the compressible foam sealing material covers substantially an entirety of the back face; and
- attaching the rigid board to the frame after said applying of the compressible foam sealing material to the rigid board,
- wherein at least a portion of the compressible foam sealing material directly contacts the frame to form an air tight seal and a moisture tight seal against the frame,
- wherein said applying the compressible foam sealing material to substantially the entirety of the back face of the rigid board comprises attaching a compressible foam gasket to substantially the entirety of the back face of the rigid board with an adhesive.
2. The method of claim 1, wherein the gasket includes a protective layer and the method further comprises removing the protective layer prior to attaching the rigid board to the frame.
3. The method of claim 1, wherein the rigid board comprises one or more of a foam board, an oriented strand board, a fiberglass reinforced sheet, and a plywood board.
4. The method of claim 1, wherein the rigid board comprises extruded polystyrene foam.
5. The method of claim 1, wherein the compressible foam sealing material is applied only to the back face.
6. The method of claim 1, wherein attaching the rigid board to the frame comprises attaching the rigid board to the frame by conventional mechanical fasteners that compress the compressible foam sealing material against the frame to form the air tight and moisture tight seal.
7. The method of claim 1, wherein the compressible foam sealing material is cured before the rigid board is attached to the frame.
8. The method of claim 1, wherein the frame comprises a plurality of spaced-apart, outer wall studs forming a structural framework for a wall.
9. The method of claim 1, further comprising:
- applying a second compressible foam sealing material to a second rigid board, wherein the second rigid board has a second front face and a second back face, wherein the second compressible foam sealing material covers substantially an entirety of the second back face; and
- attaching the second rigid board to the frame, adjacent the rigid board, after said applying of the second compressible foam sealing material to the second rigid board,
- wherein at least a portion of the second compressible foam sealing material directly contacts the frame to form an air tight seal and a moisture tight seal against the frame.
10. The method of claim 9, wherein the compressible foam sealing material forms a seal against a first frame member of the frame and the second compressible foam sealing material also forms a seal against the first frame member.
3971184 | July 27, 1976 | Van Wagoner |
4016323 | April 5, 1977 | Volovsek |
4025686 | May 24, 1977 | Zion |
4075805 | February 28, 1978 | Bongiovanni |
4107892 | August 22, 1978 | Bellem |
4121958 | October 24, 1978 | Koonts |
4232494 | November 11, 1980 | Bauch |
4241555 | December 30, 1980 | Dickens |
4244151 | January 13, 1981 | Seem |
4284447 | August 18, 1981 | Dickens |
4564554 | January 14, 1986 | Mikuski |
4687534 | August 18, 1987 | Alford |
4769963 | September 13, 1988 | Meyerson |
5086599 | February 11, 1992 | Meyerson |
5092095 | March 3, 1992 | Zadok |
5343665 | September 6, 1994 | Palmersten |
5349796 | September 27, 1994 | Meyerson |
5354402 | October 11, 1994 | Luetkens, Jr. |
5394672 | March 7, 1995 | Seem |
5448865 | September 12, 1995 | Palmersten |
5502939 | April 2, 1996 | Zadok |
5628158 | May 13, 1997 | Porter |
5756179 | May 26, 1998 | Jutte |
5820958 | October 13, 1998 | Swallow |
5834082 | November 10, 1998 | Day |
5968615 | October 19, 1999 | Schlappa |
6139945 | October 31, 2000 | Krejchi |
6158191 | December 12, 2000 | Seem |
6247281 | June 19, 2001 | Lin |
6269595 | August 7, 2001 | Blubaugh |
6314701 | November 13, 2001 | Meyerson |
6518348 | February 11, 2003 | Lee et al. |
6581348 | June 24, 2003 | Hunter, Jr. |
6715249 | April 6, 2004 | Rusek |
6922965 | August 2, 2005 | Rosenthal |
6968659 | November 29, 2005 | Boyer |
7021018 | April 4, 2006 | Peng |
7029741 | April 18, 2006 | Sjoberg |
7036285 | May 2, 2006 | Hunter, Jr. |
7146771 | December 12, 2006 | Swann |
7168221 | January 30, 2007 | Hunter, Jr. |
7188456 | March 13, 2007 | Knauseder |
7441384 | October 28, 2008 | Miller |
7603816 | October 20, 2009 | Hohmann, Jr. |
7644553 | January 12, 2010 | Knauseder |
7934353 | May 3, 2011 | Dhellemmes |
8015757 | September 13, 2011 | Hohmann, Jr. |
8112966 | February 14, 2012 | Bowe |
8151538 | April 10, 2012 | Bowe |
8286399 | October 16, 2012 | Brown |
8314161 | November 20, 2012 | Polasky |
8440296 | May 14, 2013 | Kipp |
8522500 | September 3, 2013 | Brown |
8524792 | September 3, 2013 | Polasky |
8671645 | March 18, 2014 | Shriven James |
8875462 | November 4, 2014 | Brown |
9010057 | April 21, 2015 | Trebor-MacConnell |
9068343 | June 30, 2015 | Commerford |
9267285 | February 23, 2016 | Tauferner |
9476202 | October 25, 2016 | Clancy |
10017941 | July 10, 2018 | Clancy |
20020148551 | October 17, 2002 | Knauseder |
20020189185 | December 19, 2002 | Hunter, Jr. |
20030041544 | March 6, 2003 | Rusek, Jr. |
20040031226 | February 19, 2004 | Miller |
20040031227 | February 19, 2004 | Knauseder |
20040043682 | March 4, 2004 | Taylor |
20040148894 | August 5, 2004 | Kelley |
20060096223 | May 11, 2006 | Kyoung Taek |
20060165940 | July 27, 2006 | Sjoberg |
20060183387 | August 17, 2006 | Taylor |
20070043131 | February 22, 2007 | Polasky |
20070125042 | June 7, 2007 | Hughes |
20070149628 | June 28, 2007 | Delaviz |
20070175172 | August 2, 2007 | Sousa |
20070261340 | November 15, 2007 | Cecilio |
20080086965 | April 17, 2008 | Metz |
20080216426 | September 11, 2008 | Bunker |
20090107080 | April 30, 2009 | Bowe |
20090107611 | April 30, 2009 | Bowe |
20090139181 | June 4, 2009 | Bowe |
20090308001 | December 17, 2009 | Wu |
20100095613 | April 22, 2010 | Paetkau |
20100095625 | April 22, 2010 | Boutaghou |
20100175810 | July 15, 2010 | Korwin-Edson |
20110030300 | February 10, 2011 | Liu |
20110120038 | May 26, 2011 | Wormann |
20110173925 | July 21, 2011 | Brown |
20120073225 | March 29, 2012 | Douglass |
20120148812 | June 14, 2012 | Kipp |
20120247042 | October 4, 2012 | Clancy |
20130030069 | January 31, 2013 | Polasky |
20130067841 | March 21, 2013 | Grieco |
20130111838 | May 9, 2013 | Commerford |
20130227902 | September 5, 2013 | Van Sloun |
20130312347 | November 28, 2013 | Milostic |
20130316143 | November 28, 2013 | Budinscak, Jr. |
20130318897 | December 5, 2013 | Conterno |
20130330492 | December 12, 2013 | Rogers |
20140000203 | January 2, 2014 | Brown |
20140011899 | January 9, 2014 | Polasky |
20140137501 | May 22, 2014 | Trebor-MacConnell |
20150128517 | May 14, 2015 | Tauferner |
20150353776 | December 10, 2015 | Gawryla |
20160168853 | June 16, 2016 | Letts |
20160305122 | October 20, 2016 | Clancy |
20180058748 | March 1, 2018 | Costanza |
1149096 | May 1997 | CN |
200992767 | December 2007 | CN |
201627320 | November 2010 | CN |
102008035414 | February 2010 | DE |
0255683 | February 1988 | EP |
0705999 | April 1996 | EP |
H0949269 | February 1997 | JP |
H10159194 | June 1998 | JP |
2000345653 | December 2000 | JP |
2005330664 | December 2005 | JP |
- Owens Corning brochure, CodeBord Exterior Insulating Sheathing CodeBord Air Barrier System, 4, pgs., Jul. 2007.
- Owens Corning brochure, Extruded Polystyrene Insulation FormulaR . . . in Residential Residing, 2 pgs., Jan. 2003.
- Owens Corning brochure, Propink Reinforced Insulating Sheathing Product Data Sheet, 2 pgs., 2006.
- ASTM International Designation: E2357-05, “Standard Test Method for Determining Air Leakage of Air Barrier Assemblies”, 11 pgs., 2005.
- Office action from Chinese Application No. 2012101692763 dated Jun. 2, 2016.
- Office action from Chinese Application No. 2012101692763 dated Jun. 3, 2015.
- Office action from Chinese Application No. 201210169276.3 dated Jan. 18, 2016.
- Office action from U.S. Appl. No. 13/073,170 dated May 15, 2013.
- Office action from U.S. Appl. No. 13/073,170 dated Dec. 19, 2013.
- Office action from U.S. Appl. No. 13/073,170 dated Oct. 23, 2014.
- Office action from U.S. Appl. No. 13/073,170 dated Mar. 16, 2015.
- Office action from U.S. Appl. No. 13/073,170 dated Oct. 1, 2015.
- Office action from U.S. Appl. No. 13/073,170 dated Mar. 3, 2016.
- Notice of Allowance from U.S. Appl. No. 13/073,170 dated Mar. 16, 2016.
- Notice of Allowance from U.S. Appl. No. 13/073,170 dated Jun. 17, 2016.
- Supplemental Notice of Allowance from U.S. Appl. No. 13/073,170 dated Jul. 13, 2016.
- Office action from Chinese Application No. 201210169276.3 dated Jan. 17, 2017.
- Office action from U.S. Appl. No. 15/177,664 dated Aug. 18, 2017.
- Notice of Allowance from U.S. Appl. No. 13/073,170 dated Mar. 9, 2018.
- Office action from Canadian Application No. 2,772,461 dated Aug. 20, 2018.
Type: Grant
Filed: Jun 25, 2018
Date of Patent: Apr 9, 2019
Patent Publication Number: 20180334806
Assignee: Owens Corning Intellectual Capital, LLC (Toledo, OH)
Inventors: Timothy Robert Clancy (Swanton, OH), John Frank Budinscak, Jr. (Wadsworth, OH), Leandro John Burlingame (Toledo, OH)
Primary Examiner: Rodney Mintz
Application Number: 16/017,151
International Classification: B32B 5/18 (20060101); B32B 7/12 (20060101); E04B 1/24 (20060101); E04B 1/61 (20060101); E04B 1/68 (20060101); E04B 1/80 (20060101); E04B 2/56 (20060101); E04B 2/70 (20060101); E04B 2/74 (20060101); E04C 2/24 (20060101); E04C 2/30 (20060101); E04C 2/52 (20060101); B32B 21/02 (20060101); B32B 37/12 (20060101); E04F 13/08 (20060101);